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69-1

Seat belts

Safety precautions for handlingpyrotechnic seat belt tensioners

WARNING!

Testing, removing, installing and repair work

must only be carried out by properlyqualified personnel.

When connecting the seat belt tensioner unit ,all mechanical components (including thoseof the three-point seat belt) must be properlyattached.

Only the technician carrying out the workmay be present inside the vehicle.

The seat belt tensioner components cannotbe opened or repaired; always use newcomponents.

Seat belt tensioner units which have beendropped from a height of more than 20inches must not be installed in a vehicle.

Seat belt tensioner units which aremechanically damaged (dents, cracks) must

always be replaced.

Page 1 of 41Seat belts

11/20/2002http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD03.69.1

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The seat belt tensioner unit should not beremoved from its packaging until just before

it is to be installed.

If the installation work is interrupted, returnthe seat belt tensioner uni t to i ts packaging.

Never point the open end of a seat belttensioner at another person.



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69-2

WARNING!

Always wash your hands after handling seatbelt tensioners which have been triggered.

Observe all transpor tation regulations forexplosive substances.

Do not leave an uninstalled seat belttensioner unit unattended.

Seat belt tensioner units must not be treatedwith grease, cleaners or simi lar substances.

Seat belt tensioner units must not be

exposed to temperatures above 100 C (212

F), even for short periods.



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69-3

Pyrotechnic seat belt tensioners,disposal

WARNING!

Improper disposal of pyrotechnic seat belttensioner units (gas generators) which havenot been triggered creates a hazard.

Pyrotechnic seat belt tensioner units (gasgenerators) must be rendered inoperablebefore disposing because pyrotechnicdevices can cause injury if disposed ofimproperly (e.g. using a blow torch).

Seat belts which need to be removed (e.g.after an accident in which the seat belttensioner was not activated) must betriggered before removal.

This does not apply to seat belts withmalfunctions (e.g. sticking or failure toretract) which must be returned to theWarranty Parts Test Center for analysis.

Observe all transpor tation regulations forexplosive substances.

Procedure for rear belt tensioners is



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analogous to front (shelf, remove trim onside of tr im or remove 2/3 of backrest cover).




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69-4

Procedure for triggering pyrotechnic belttensioners

Notes:

Whenever possible, pyrotechnic belt tensionersmust be deployed outside the vehicle. Use

Airbag and Pyrotechnic Deployment Device J-

44210 and follow instructions in booklet.

The procedure that follows is for deployment oftensioners mounted inside a vehicle.

- Remove upper B-pillar trim page 70-75.

- Remove lower B-pillar trim page 70-75.

- Remove outer seat belt anchor page 69-

13.

- Using scissors, cut belt webbing above seat belt

tongue (about 20 cm above belt retractor).

- Disconnect harness connector from beltretractor and connect wiring harness (Part No.8D1 971 259) to belt tensioner.

-Cut harness connector at opposite end, insulate




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both ends of cable, pull cable housing apart untilends of cable are at least 30 cm apart.

Vehicle must not be occupied

- Open windows and close doors.

- Using wiring harness and an external battery

(located outside vehicle), activate gas generator(maintain minimum 10 m distance).




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69-5

- Air out vehicle after triggering.

After removal, the belts can be disposed of ascommercial waste.

Wash your hands after handling belt tensionersthat have fired.

Follow safety and handling instructions forpyrotechnic belt tensioners.




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69-6

Seat belt attachment points, overview

1 -Three-point seat belt wi th seat belt heightadjuster and belt tensioner

Removing page 69-7

2 -Buckle attachment point

Removing page 69-12

3 -Attachment point for outer floor assembly

Removing page 69-13

4 -Left and right-rear three-point seat belt

Sedan:

Removing page 69-15

Avant:

Removing page 69-18

5 -Rear center three-point seat belt

Floor rear backrest

Removing page Page 69-22

6 -Attachment point for center floorassembly

Removing page 69-25




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69-7

Three-point seat belt wi th seat belt heightadjuster and belt tensioner, removing andinstalling

Notes:

Function check after installing trim:

1 -Seat belt height adjuster

Removing:

- Remove upper B-pillar trim page 70-

75.

- Remove shouldered nut -3- and bolt -2-.

- Remove seat belt height adjuster -1- up

and out of position -A-.

Installing:

- Guide seat belt height adjuster switch -4-into height adjuster assembly -1-.

Do not press switch -4- when installing.

Height adjuster must audibly engage intoall five of the possible positions (even inthe top position).

Switch must return by itself to upperposition after being actuated.

g



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69-8

2 -Bolt

23 Nm (17 ft lb)

3 -Shouldered nut

50 Nm (37 ft lb)

4 -Switch for height adjustment

5 -Belt guide

- Remove bolts -7- (2x).

Unclip lower part of belt guide, swingupward and detach

6 -Bolts (2x)

2 Nm (18 in. lb)

7 -Bolt

50 Nm (37 ft lb)

8 -Bolt

50 Nm (37 ft lb)



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69-9

Note:

Arrow -B- indicates direction of travel.

9 -Belt tensioner

Removing three-point seat belt:

- Disconnect battery.

- Removing sill molding page 70-80.

- Remove bolt -9- (1x).

- Remove upper B-pillar trim page 70-75.

- Remove belt webbing from upper B-pillartrim.

- Remove lower B-pillar trim page 70-75.

- Remove shouldered nuts -3-.

- Disconnect harness connector -C- at belt

tensioner.

- Remove bolt -7-.

- Remove belt tensioner -9- upward out of

anti-twist stop -11-.

Installing three-point seat belt:

- Install belt tensioner -9- with anti-twist

stop -11- as shown in magnified area.



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- Install belt webbing (turned 180 ) as

shown in illustration (arrow).



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69-10

Lower belt webbing must be bolted to metalstud -10- as shown in magnified area

Remainder of installation is reverse of removal

- After installing passenger side three-

point seat belt, check belt function forchild seat page 69-37.

Three-point seat belt must not be hinderedby cables, wires or dampening material etc

10 -Metal stud in floor pan

Anti-twist stop for belt webbing bracket

11 -Anti -twist s top and reverse-mount ingprotection for three-point safety belt



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69-11

Fig. 1 Installing upper B-pillar trim in belt height adjuster

- Guide slide with button -4- (without pressing) beginning at top andworking downward into release lever -1- of height adjuster whilesimultaneously installing pin -2- into mounting -3-.



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69-12

Belt buckle attachment point

- Remove seat page 72-2.

1 - Buckle

4 - Spring washer

- Remove bolt -3-.

Tightening torque: 60 Nm (44 ft lb)

- If necessary, disconnect harness connector -2- for belt warning.



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69-13

Outer floor assembly attachment point

Mounting bracket -2- must be located in impression -3- of floor assembly.

- Remove bolt -1-.




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69-14

Recaro seat buckle, removing andinstalling

- Remove seat page 72-25.

- Turn buckle -1- downward to allow access to bolt -2-.

- Remove bolt -2-.




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69-15

Left and right-rear three-point seat belts,removing and installing

Sedan

1 -Belt guide trim

Large symbol must always point toward

vehicle center2 -Belt adjuster cover

3 -Retaining tab

4 -Belt adjuster

Removing and installing page 69-20

5 -Three-point seat beltRemoving:

- Remove rear seat page 72-57.

- Remove bolt -7-.

- Unclip belt guide trim -1-.

- Detach belt adjuster cover -2- at left andright of retaining tab -3-.

- Remove rear shelf page 70-83.

- Open cover for side trunk trim.



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69-16

Note:

The igniter wire -11- must not be located near the

belt webbing.

Vehicles with CD player and/or subwoofer orsimilar:

- Remove side trunk trim page 70-87.

Vehicles with belt tensioners:

- Unclip igniter wire -11- at clip -10-.

- Detach harness connector for igniter wire

at clip -9-.


- Detach seat belt against direction of

arrow.

Installing:

Make sure harness connector for igniterwire -11- engages

- Clip igniter wire -11- into clip -10-.

For vehicles with belt tensioner, check belt-fastened sensor page 69-38

After installing rear three-point seat belt,check belt function for child seat page69-37



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Three-point seat belt must not be hinderedby cables, wires or dampening material, etc



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69-17

6 -Bolt

50 Nm (37 ft lb)

7 -Bolt

50 Nm (37 ft lb)

8 -Three-point seat belt wi th belt tensioner

9 -Clip

10 -Clip

11 -Igniter wire



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69-18

Avant

1 -Bolt

50 Nm (37 ft lb)

2 -Belt tensioner

Removing:

- Remove left and right-rear side bolsterspage 72-75.

- Remove left and right-side trunk trimpage 70-87.



Vehicles with belt tensioners:

- Unclip igniter wire -11- at clip -10-.

- Detach harness connector for igniter wire

at clip -8-.


- Detach seat belt against direction ofarrow.

Installing:

- Make sure harness connector for igniter

wire -11- engages.

- Clip igniter wire -11- into clip -10-.



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Note:

The igniter wire -11- must not be located near the

belt webbing.



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69-19

For vehicles with belt tensioner, check belt-fastened sensor page 69-38

After installing rear three-point seat belt, checkbelt function for child seat page 69-37

The three-point seat belt must not be hinderedby cables, wires or dampening material, etc

3 -Bracket 4 -Bolt

50 Nm (37 ft lb)

5 -Bracket

6 -Bolt

2.5 Nm (22 in. lb)

It is not necessary to remove metal bracketwhen removing belt

7 -Three-point seat belt wi th belt tensioner

8 -Clip

9 -Clip

10 -Igniter wire



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69-20

Rear belt adjuster, removing andinstalling

Removing

Note:

It is not necessary to remove the rear shelf when

removing the rear belt adjuster.

- Undo lower attachment point of rear three-point seat belt.


- Unclip belt guide trim -3-.

- Detach belt adjuster cover -2- at left and right of retaining tab -7-.

- Swing belt adjuster -4- with belt webbing upward.

- Use screwdriver to press retaining tab -1- (2x) inward whilesimultaneously pulling up on belt adjuster -2-.

- Pull belt webbing through belt adjuster -2-.


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69-22

Third rear center three-point seat belt(Avant), removing and installing

Removing


- Remove bolt -7-.

- Remove 2/3 seatback ( m.y. 97) page 72-62, (m.y. 98 ) page 72-64.

- Push cover at belt guide trim -6- to side, andusing screwdriver, detach retaining tab -11-.

- Remove cover -6- in direction of arrow -A-.

- Remove padding of 2/3 rear seatback until cover

with padding can be removed page 74-37.


- If necessary, disconnect harness connector atbelt tensioner.

- Cut tie wrap off belt tensioner igniter wire at belttensioner.



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69-23

Installing

Vehicles with belt tensioner:

Notes:

Check the following after full backrest installation:

- Remove nut -2- (1x) and third rear three-pointseat belt tensioner -3-.

- To install belt guide trim -6-, first attach retainingtab -10- and insert, then turn retaining tab -11-inward making sure metal piece -12- is inserted

into cutout -13- of belt guide trim -6- (arrow -B- ininset).

- Tap lightly on belt guide trim -6- in direction ofarrow -C- to engage.

- Check belt-fastened sensor page 69-38.

The anti-twist stop -4- and belt webbing -5-

must not touch or rub against any foam or covercomponents.

Anti-twist stop -4- must follow all movements ofbelt webbing.

Belt webbing -5- must move freely in alldirections.



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69-24

1 -Bolt55 Nm (41 ft lb)

2 -Nut

55 Nm (41 ft lb)

3 -Belt tensioner

4 -Anti -twist stop

5 -Belt webbing

6 -Belt guide trim

7 -Bolt (1x)

8 -Retaining tab

9 -Harness connector for belt tensioner

10 -Retaining tab

11 -Retaining tab

12 -Bracket on rear backrest

13 -Cutout



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69-25

Center floor panel attachment poin ts

Removing



Always change gasket -2-.

When installing, make sure buckle and/or lapbelt engages in guide knob -4-.

Narrow side of buckle and/or lap belt must facein direction of travel.



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69-26

Note:

When installing, make sure that bracket isaccessible. If necessary, turn lap belt with retractor.

1 -Lap belt with retractor

2 -Seal

3 -Buckle

4 -Guide knob

5 -Bolt

50 Nm (37 ft lb)

Only use genuine Audi replacement bolts

6 -Lap belt



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69-27

LATCH system, "Lower Anchors andTethers for CHildren" , installing,removing, retrofitting (Sedan)

Rear upper tethers, installing

Note:

Mountings can be installed for three upper tetherattachment points.


1 -Cover

2 -Cap

- To install, attach at front and press indirection of arrow and downward.

3 -Bolt

23 Nm (17 ft lb)

4 -Attachment point

5 -Spacer



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69-28

CAUTION!

The thread washer must always be installedfrom below (trunk side).

6 -Pop rivetQty: 3 per plate

To secure thread washer -7- on metalmounting

Riveted from above (interior)

7 -Threaded washer

Secured on trunk side with pop rivets -6-

Threaded insert points upward



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69-29

Rear upper tethers, retrofitt ing

CAUTION!

The thread washer must always be installedfrom below (trunk side).

- Beginning in trunk, use felt tip marker to markcenter point of center holes (3x).


- Install threaded washer -7- starting from trunk.

- Cut 23 mm hole at each marked point (3x).

- Install rear shelf.

1, 2, or 3 attachment stops can be installed asneeded.

- Install spacer sleeve and secure attachment stopwith bolt -3-.

- Close other holes using cover -1-.



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69-30

Rear lower anchors, installing

Notes:

1 -Rear lower anchor bracket

- Remove rear seat page 72-57

- Disconnect connectors


2 -Bolts (4x)

30 Nm (22 ft lb)

- Mount rear lower anchor bar -1- with

bolts -2- fastened into threaded holes inbody floor panel.

To install solid rear backrest, push tabsbehind rear lower anchor bracket.

If rear lower anchor is retrofitted, it may benecessary to flatten tab in vise down toabout 3 mm page 72-58

Inside anchors are not recommended for

attaching rear lower anchors of a LATCHseat in the middle position. The three-pointlap/shoulder belt should be used.



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69-31

LATCH system, "Lower Anchors and

Tethers for CHildren" , installing,removing, retrofi tting (Avant)

Rear upper tethers

Note:

Some A4 Avant models may require a seat backchange for rear top tether installation.

Rear upper tethers (Avant), retrofitting (m.y. 1998)

To retrofit the child seat attachment point on

vehicles m.y. 1998, a backrest from m.y. 1999

or later must be installed.

- Remove old backrest.

Repair Manual Body Interior Repair Group 72

1/3 backrest

- Using sharp knife, carefully cut upholstery -1- at width of 30 mm(dimension -B-) down to indentation -2- (dimension -A- = 195 mm whenmeasured from below).



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69-32

2/3 backrest

- Using sharp knife, carefully cut upholstery atreinforcements.

Al l backrests

- Install new panel on backrest.

Note original color and cargo net version.



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69-33

Rear upper tethers (Avant), retrofitting (

m.y. 1998)

To retrofit the child seat upper tether points on

vehicles m.y. 1998, a backrest from m.y. 1999or later must be installed.

- Remove old backrest.

Repair Manual Body Interior Repair Group 72

1/3 backrest

2/3 backrest

Al l backrests

- Using sharp knife, carefully cut upholstery -1- at width of 30 mm(dimension -B-) down to indentation -2- (dimension -A- = 195 mm whenmeasured from below).

- Using sharp knife, carefully cut upholstery at reinforcements.

- Install new panel on backrest.

Note original color and cargo net version.



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69-34

Rear upper tethers (Avant), removing and

installing (m.y. 1999 )

1 -Cap

To install, attach at front and pressdownward in direction of arrow

2 -Bolt

23 Nm (17 ft lb)

3 -Attachment point

4 -Spacer pulley

5 -Backrest

6 -Plugs

Remove if necessary and attach items -1-through -4-



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69-35

Rear lower anchors, installing

Notes:

1 -Rear lower anchor bracket

- Remove rear seat page 72-57

- Disconnect connectors


2 -Bolts (4x)30 Nm (22 ft lb)

- Mount rear lower anchor bar -1- with

bolts -2- fastened into threaded holes inbody floor panel.

To install solid rear backrest, push tabsbehind rear lower bracket.

If rear lower anchor is retrofitted, it may benecessary to flatten tab in vise down toabout 3 mm page 72-58

Inside anchors are not recommended for

attaching rear lower anchors of a LATCHseat in the middle position. The three-pointlap/shoulder belt should be used.


Documents

69 1 Seatbelt